Abstract: Melt processed polyarylene sulfide compositions are described as are methods of forming the melt processed polyarylene sulfide compositions. The melt processed polyarylene sulfide compositions are formed according to a melt processing method that includes melt processing a mixture that includes a starting polyarylene sulfide, a disulfide compound and a filler. The melt processed polyarylene sulfide compositions may provide low chlorine content products having excellent strength characteristics.

Abstract: Pipe sections and methods for forming pipe sections are disclosed. A pipe section includes a hollow body formed from a metal material, the hollow body having an inner surface and an outer surface, the inner surface defining an interior. The pipe section further includes a barrier layer surrounding and bonded to the hollow body, the barrier layer having an inner surface and an outer surface. The barrier layer is formed from a continuous fiber reinforced thermoplastic material. Such pipe sections may be lightweight and flexible while exhibiting improved strength characteristics.

Abstract: Pipe sections and methods for forming pipe sections are disclosed. A pipe section includes a hollow body, the hollow body having an inner surface and an outer surface, the inner surface defining an interior. The pipe section further includes a barrier layer surrounding the hollow body, the barrier layer having an inner surface and an outer surface. The barrier layer is formed from a polyarylene sulfide composition. The polyarylene sulfide composition includes a polyarylene sulfide and a crosslinked impact modifier. Such pipe sections exhibit high strength characteristics and flexibility as well as resistance to degradation, even in extreme temperature environments, while maintaining desirable processing characteristics.

Abstract: Disclosed are porous elements that include sintered polymeric particles. The polymeric particles can be formed of a thermoplastic composition that includes a polyarylene sulfide. The polymeric particles sintered to form the porous elements have a very narrow size distribution. The porous elements can maintain their functionality and morphology even when utilized in high temperature applications.

Abstract: Pipe sections and methods for forming pipe sections are disclosed. A pipe section includes a hollow body, the hollow body having an inner surface and an outer surface, the inner surface defining an interior. The pipe section further includes a barrier layer surrounding the hollow body, the barrier layer having an inner surface and an outer surface. The barrier layer is formed from a polyarylene sulfide composition. The polyarylene sulfide composition includes a polyarylene sulfide and a crosslinked impact modifier. Such pipe sections exhibit high strength characteristics and flexibility as well as resistance to degradation, even in extreme temperature environments, while maintaining desirable processing characteristics.

Abstract: A method for injection molding a thermoplastic composition that contains a polyarylene sulfide and an aromatic amide oligomer is provided. Due to the improved crystallization properties imparted by the oligomer, the present inventors have discovered that the thermoplastic composition can be molded at lower temperatures to still achieve the same degree of crystallization. In addition to minimizing the energy requirements for the molding operation, such low mold temperatures may be accomplished using heating mediums that are less corrosive and expensive than some conventional techniques.

Abstract: An injection molded housing for a portable electronic device is provided. The housing contains a thermoplastic composition that includes a polyarylene sulfide melt processed in the presence of a disulfide compound and a filler. Without intending to be limited by theory, it is believed that the disulfide can undergo a chain scission reaction with the starting polyarylene sulfide to lower its melt viscosity, which can lead to decreased attrition of the filler and thus improved mechanical properties. Due to this ability to reduce viscosity during melt processing, the present inventors have discovered that relatively high molecular weight polyarylene sulfides can be fed to the extruder with little difficulty.

Abstract: A polymer composition that comprises a polyarylene sulfide, inorganic fibers, impact modifier, and a functionalized coupling system is provided. The functionalized coupling system includes a disulfide compound and an organosilane compound. The weight ratio of organosilane compounds to disulfide compounds is from about 0.1 to about 10.

Abstract: A polymer composition containing a polyarylene sulfide, a disulfide compound, and inorganic fibers is provided. The polymer composition has an aspect ratio of from about 1.5 to about 10, wherein the aspect ratio is defined as the cross-sectional width of the fibers divided by the cross-sectional thickness of the fibers.

Abstract: A nucleating system for a thermoplastic composition that contains a polyarylene sulfide is provided. The nucleating system includes a combination of an inorganic crystalline compound and an aromatic amide oligomer. The present inventors have discovered that the combination of these different types of nucleating agents result in excellent crystallization properties (e.g., rate of crystallization). Due to the improved crystallization rate, the thermoplastic composition can be molded at lower temperatures to still achieve the same degree of crystallization. In addition to minimizing the energy requirements of the molding operating, the use of lower temperatures can also decrease the production of “flash” normally associated with high temperature molding operations. The composition may also possess good viscosity properties that allow it to be readily molded into parts of a variety of different shapes and sizes.

Abstract: A thermoplastic composition that contains a unique combination of a thermotropic liquid crystalline polymer, dielectric material, laser activatable additive, and a fibrous filler is provided. The nature of the components and/or their concentration are selectively controlled in the present invention to maintain a high dielectric constant, good mechanical properties (e.g., deflection under load), and good processibility (e.g., low viscosity), yet still be laser activatable. Thus, the thermoplastic composition can be readily shaped into a thin substrate and subsequently applied with one or more conductive elements using a laser direct structuring process (“LDS”).

Abstract: Conductive thermoplastic compositions are described that exhibit low permeability, high strength and flexibility. Methods for forming the thermoplastic compositions are also described. Formation methods include dynamic vulcanization of a thermoplastic composition that includes carbon nanotubes and an impact modifier dispersed throughout the polyarylene sulfide. A crosslinking agent is combined with the other components of the composition following dispersal of the impact modifier throughout the composition. The crosslinking agent reacts with the impact modifier to form crosslinks within and among the polymer chains of the impact modifier. The compositions can exhibit excellent physical characteristics at extreme temperatures and can be used to form conductive tubular member such as pipes and hoses and fibers.

Abstract: Polyarylene sulfide/liquid crystal polymer alloys are described as are methods of forming the polyarylene sulfide/liquid crystal polymer alloys. The polyarylene sulfide/liquid crystal polymer alloys are formed according to a melt processing method that includes melt processing a polyarylene sulfide with a reactively functionalized disulfide compound and a liquid crystal polymer in a one or two step process. The reactively functionalized disulfide compound is added in a stoichiometric amount to react with a portion of the polyarylene sulfide. The melt processing forms a polyarylene sulfide/liquid crystal polymer copolymer that is a compatibilizer in the alloy. The polyarylene sulfide/liquid crystal polymer alloys may provide low chlorine content products having excellent strength characteristics.

Abstract: Thermoplastic compositions are described that exhibit resistance to hydrocarbon absorption. Methods for forming the thermoplastic compositions are also described. Formation methods include combining a polyarylene sulfide with a first impact modifier and a second impact modifier such that the impact modifiers are dispersed throughout the polyarylene sulfide. A crosslinking agent can be combined with the other components of the composition following dispersal of the additives throughout the composition to dynamically crosslink at least one of the first and second impact modifiers.

Abstract: Injection molded parts with a small dimension that exhibit high heat resistance are described. Thermoplastic compositions that can be utilized to form the injection molded parts are described. The thermoplastic composition includes a polyarylene sulfide and a crosslinked impact modifier. The thermoplastic composition can also include siloxane polymers, thermoplastic elastomers, or other additives that can further improve the characteristics of the injection molded parts.

Abstract: Methods for forming a low chlorine content washed polyarylene sulfide are described. Methods include washing a polyarylene sulfide that includes aryl halide endgroups with a solution that includes a disulfide compound. The solution can also include a catalyst and an organic solvent. During the disulfide wash, a nucleophilic substitution reaction occurs between the disulfide compound and aryl halides endgroups of the polyarylene sulfide. The nucleophilic substitution reaction is carried out at conditions to prevent chain scission of the polyarylene sulfide that includes the aryl halide endgroups. Compositions and products formed with the low chlorine content disulfide washed polyarylene sulfide are also described.

Abstract: A method for injection molding a thermoplastic composition that contains a polyarylene sulfide and an aromatic amide oligomer is provided. Due to the improved crystallization properties imparted by the oligomer, the present inventors have discovered that the thermoplastic composition can be molded at lower temperatures to still achieve the same degree of crystallization. In addition to minimizing the energy requirements for the molding operation, such low mold temperatures may be accomplished using heating mediums that are less corrosive and expensive than some conventional techniques.

Abstract: Low VOC emission polyoxymethylene and compositions and products that incorporate the polyoxymethylene are described. The polyoxymethylene is end capped with compound that can prevent degradation of the polymer and subsequent emission of VOC degradation products such as formaldehyde. The end-capped polyoxymethylene can include an inorganic linkage within the polymer backbone that is the reaction product of a terminal hydroxyl group of the polyoxymethylene and a hydrolyzable group of the compound. Also disclosed are products as may be formed from the low VOC emission polyoxymethylene.

Abstract: A method for injection molding a thermoplastic composition that contains a polyarylene sulfide and an aromatic amide oligomer is provided. Due to the improved crystallization properties imparted by the oligomer, the present inventors have discovered that the thermoplastic composition can be molded at lower temperatures to still achieve the same degree of crystallization. In addition to minimizing the energy requirements for the molding operation, such low mold temperatures may be accomplished using heating mediums that are less corrosive and expensive than some conventional techniques.

Abstract: An overmolded composite structure that contains a metal component and a resinous component adhered to a surface thereof is provided. The resinous component is formed from a thermoplastic composition that contains at least one polyarylene sulfide and at least one mineral filler. The present inventors have discovered that the nature and relative concentration of the polyarylene sulfides, mineral fillers, and/or other materials in the thermoplastic composition can be selectively tailored so that the resulting resinous component has a coefficient of linear thermal expansion and/or color that is similar to the metal component.